Plant control monitor

ABSTRACT

An object of the present invention is to quickly and accurately detect disorder or abnormality of a process state which occurs in a plant and to appropriately perform an operation for normalizing disorder or abnormality of the process without depending on experience or skill of an operator. 
     A control system of the plant is divided into groups having relation, such as, the plant, processes, or steps, and a monitor picture is created for each of them. When an alarm is raised, the alarm is displayed on a picture associated with the alarm. A guidance picture for supporting how to deal with the alarm is provided.

DESCRIPTION

1. Technical Field

The present invention relates to a system for monitoring operationcontrol of various manufacturing plants for manufacturing products, suchas chemical product manufacturing plants, petroleum chemical productmanufacturing plants, oil refining plants, iron and steel productmanufacturing plants, food manufacturing plants, paper and pulp productmanufacturing plants, drug manufacturing plants, automobilemanufacturing plants, mechanical product manufacturing plants, orelectric appliance manufacturing plants, or power plants, wastetreatment plants, and the like.

2. Background Art

Conventionally, a distributed control system (DCS) and an upper computersystem for controlling and monitoring the DCS have been used to controland monitor operations of manufacturing plants. These are called plantcontrol monitoring systems.

The DCS comprises a CRT or liquid crystal display device for displayingoperating states of devices or equipment, or processes within the plant,thereby controlling and monitoring the plant. The conventional displaydevice generally displays a graphic picture describing the process ofthe plant in the form of a process flow diagram (P & ID). This makes itpossible to visually check a control state of the plant.

The upper computer system is configured to output a management valuerequired for optimum operation in terms of quality, efficiency, safetyof installation or process, etc, based on a process state signal or avariable which is delivered from the DCS, or based on a process signalobtained by processing the process state signal or the variable asdesired. An operation manager (operator) totally judges theseinformation, and performs some activity (action) on the operation of theplant.

In the conventional plant control monitoring system, when the processstate signal or the process signal to be handled by an instrument (suchas a pressure indicator, a temperature indicator, a flow rate indicator,or a liquid level indicator) which is installed on the plant, exceeds apreset reference value, an alarm is notified for each instrument.

In the conventional plant control monitoring system, graphicrepresentation is displayed on a screen of the display device usingdiagrams, symbols, texts, and the like, for each instrument. When thealarm is raised (a certain deviation state occurs in the process), thediagram, the symbol, or the texts is individually color-changed orblinked, thus notifying the operator of the alarm. When the instrumentsare represented by means of the diagrams, the symbols, the texts, andthe like and the entire plant is represented by the graphic picture, aplurality of graphic pictures are needed. In particular, a huge plantrequires a great many graphic pictures.

Upon the alarm being raised in the plant using the plurality of graphicpictures, it is necessary to check this alarm and display a picturerepresenting required operation (picture including the device orequipment in the deviation state). To this end, conventionally, thepictures are numbered and by entering a number, the correspondingpicture is displayed, or pictures where alarms tend to appear arestatistically or empirically specified, and are displayed through onetouch by a picture switching means provided on a key board or the likeat the time when the alarm is raised. Or, alternatively, a number of CRTpictures are prepared and specific pictures among them, where alarmstend to appear, are always displayed.

The conventional plant control monitoring system has problems asdescribed below.

In order to quickly display a required picture when an alarm is raised,the operator needs to remember numbers of the respective pictures. But,the number of pictures which the operator can remember is limited.

When the entire plant is represented by a plurality of pictures, aplurality of CRT or liquid crystal devices, and a plurality of operatorsare necessary to monitor a wide range of the process, and frequentpicture switching is necessary in actual monitoring.

In other words, since the range of the plant which can be monitored byone operator, i.e., the number of instruments which can be monitored byone operator is limited, a number of operators and display devices andfrequent picture switching are needed for monitoring the plant includinga great many instruments.

On the other hand, when disorder or abnormality of the process statethat has occurred in the plant causes alarms relating to a number ofinstruments in a chain reaction. In that case, the operator must quicklyand accurately detect a cause of the disorder or abnormality (origin ofmany alarms). Further, the operator needs to perform some operation tonormalize the disorder or abnormality in the process. In that case, theoperator needs to find out the associated process state signal or theassociated instrument, and perform some operation based on theseinformation.

Specification of the cause of the alarm or judgment or handling of thedisorder or abnormality varies from operator to operator depending ontheir technical and empirical abilities. This makes it difficult toachieve stable and safe operation of the plant and uniform quality ofproducts.

DISCLOSURE OF THE INVENTION

The present invention has been developed under the circumstances. Anobject of the present invention is to provide a plant control monitoringsystem capable of quickly and accurately detecting disorder orabnormality in a process state which occurs in a plant. Another objectof the present invention is to provide a plant control monitoring systemcapable of appropriately performing an operation for normalizing thedisorder or abnormality of the process without depending on experienceor skill of the operator.

To achieve the above objects, inventors discovered that, if a displaydevice has a required layer picture structure including from an upperpicture representing the entire plant to a lower picture representingindividual devices or equipment included in the plant and a picture ineach layer is displayed as desired, then which of points being measuredabnormality has occurred on is detected quickly and accurately and anoperation for dealing with the abnormality is appropriately performed.

(1) According to the present invention, there is provided a plantcontrol monitoring system comprising: a display device configured todisplay operating stales of a plurality of devices or equipment includedin each process of a plant by using predetermined symbols; and aprocessing unit having an alarm output portion for outputting an alarmsignal and causing the display device to display an alarm, when judgingthat an operation of a device or equipment is in a deviation state; thedisplay device including: a first layer picture configured to representan operating state for each device or equipment, and an upper layerpicture configured to represent an operating state for each of groupsinto which devices or equipment are hierarchically divided so as to beassociated with one another; a simple display means for simplydisplaying a simple display portion configured to simply display anoperating state of a lower layer group, the same layer group, or anupper layer group, on the first layer picture or the upper layerpicture; and a picture switching means for switching picture display asdesired.

In accordance with this configuration, the picture switching means iscapable of performing switching of the picture displayed by the displaydevice as desired. Specifically, the picture switching means is capableof performing switching from the first layer picture to the upper layerpicture as desired. The alarm output means displays the alarm. When thealarm is raised in a device or equipment, a picture including the deviceor equipment being in a disorder state is easily displayed by sequentialswitching from the upper to lower picture.

In addition, when a picture in a layer is being displayed, the simpledisplay means can simply display a picture in a lower layer, the samelayer or an upper layer. So, when the deviation state has not occurredin another device or equipment included in the picture being displayedbut has occurred in a device or equipment included in another picture,it is possible to display an event that the alarm has been raised in agroup to which the picture including the device or equipment being inthe deviation state belongs.

Specifically, when a first layer picture including a device or equipmentis being displayed and an alarm appears in another first layer pictureincluding another device or equipment, this is simply displayed.

The upper layer picture includes at least a plant-base layer pictureconfigured to represent the entire plant as having groups into whichsteps represented by the first layer pictures are divided so as to beassociated with one another.

With this configuration, in the case where the picture representing theentire plant is displayed, when a deviation state occurs in a device orequipment, thereby causing an alarm to be raised, it is possible toperform switching to the first layer picture to which this device orequipment belongs.

The upper layer picture includes at least a process-base layer pictureconfigured to represent groups into which steps represented by the firstlayer pictures are divided for each process; and a plant-base layerpicture configured to represent processes represented by theprocess-base layer pictures as being integrated for each plant.

With this configuration, in the case where the picture representing theentire plant is being displayed, when a deviation state occurs in adevice or equipment, thereby causing an alarm to be raised, it ispossible to perform switching to a process-base layer picture includinga process to which the corresponding device or equipment belongs andthen to a first layer picture representing a step included in theprocess.

(2) The alarm output means includes an alarm grouping means configuredto display the alarm in a first layer picture associated with the alarmand an upper layer picture associated with the first layer picture, whenoutputting the alarm signal.

With this configuration, when the alarm is raised while any one layerpicture is displayed, the alarm can be displayed in all picturesassociated with the alarm. Therefore, by tracing the alarm by sequentialswitching from a layer picture being displayed, it is possible to easilyand quickly reach the picture including the device or equipment being inthe deviation state.

The alarm grouping means includes a display configuration changing meansfor changing a display configuration according to importance of thealarm.

With this configuration, it is possible to recognize importance of thealarm and predict what type of deviation state has occurred, in additionto detection of the alarm.

(3) The display device includes a guidance picture configured torepresent a deviation state and support information for dealing with thedeviation state when the alarm is raised.

With this configuration, it is possible to correctly recognize thedeviation state from the guidance picture, and according to the guidancepicture, an operation for dealing with the alarm can be easilyperformed.

The display device includes a means configured to display a pictureindicating that the guidance picture is prepared, when the alarm israised.

With this configuration, when the alarm is raised, the operator canrecognize that the picture for recognizing the deviation state andsupporting how to deal with the deviation state is present.

(4) The picture switching means includes a means configured to displaythe guidance picture when the alarm is raised.

With this configuration, the picture switching means displays theguidance picture. In this case, the guidance picture can beautomatically displayed.

The picture switching means includes a means configured to display theguidance picture or a picture indicating that the guidance picture isprepared, when an alarm having a predetermined rating is raised.

With this configuration, the support information can be displayed onlyfor important alarm requiring guidance. Thereby, processing becomessimple in contrast to the case where guidances for all the alarms arepresented. The operator can recognize that the alarm is important.

The guidance picture may be configured to represent a plurality ofsupport information for dealing with the alarm.

With this configuration, a plurality of measures for dealing with thealarm can be presented, and the alarm can be dealt with appropriately.

(5) The guidance picture has a list picture configured to represent alist of a plurality of guidances.

With the list picture, it is possible to clearly know what guidancepicture is prepared.

(6) The picture switching means includes a means configured to performswitching to a layer picture different from a layer picture beingdisplayed or the guidance picture, by one touch operation on the layerpicture being displayed.

With this configuration, since the picture switching can be performed byone touch operation, the picture switching can be quickly performed todisplay a desired picture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view showing a configuration of a plant controlmonitoring system according to an embodiment of the present invention;

FIG. 2 is a view showing a picture displayed by a display deviceaccording to the embodiment of the present invention;

FIG. 3 is a view of a list of pictures capable of being displayed by thedisplay device according to the embodiment of the present invention;

FIG. 4 is a view showing an example of picture switching by the displaydevice according to the embodiment of the present invention;

FIG. 5 is a view showing an example of an process-base layer picture;

FIG. 6 is a view showing an example of a step-base layer picture;

FIG. 7 is a view showing an example of a first layer picture;

FIG. 8 is a view showing an example of a simple display portion;

FIG. 9 is a view showing a guidance picture being displayed;

FIG. 10 is a view showing a list of guidance pictures; and

FIG. 11 is a view showing how the guidance picture is switched.

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, an embodiment of the present invention will be described.

FIG. 1 is a schematic view showing a configuration of a plant controlmonitoring system according to an embodiment of the present invention.In FIG. 1, a manufacturing plant 10 and a plant control monitoringsystem 13 for controlling the manufacturing plant 10 are independentlyillustrated.

In this embodiment, the plant 10 is an integrated producing plant formanufacturing chemical products. The plant 10 includes various devicesor equipment. The devices or equipment include chemical rectors,distilling devices, heat exchangers, compressors, pumps, tanks, piping,and so forth. For each device or equipment, a sensor 11, an actuator ofa valve 12 or the like, and the like are installed at predeterminedlocations. The sensor 11 includes a temperature indicator, a flow rateindicator, a pressure indicator, a liquid level indicator, adensitometer, and the like. The sensor 11 monitors an operating state(process state) of each device or equipment and outputs a signalindicative of the state.

The plant control monitoring system 13 manages and controls theoperating state of the plant 10 and manages a producing state of theplant 10. The plant control monitoring system 13 comprises controlstations 14 (processing units) and a display device 15. In thisembodiment, a plurality of control stations 14 are provided. This isbecause a control system of the plant 10 is divided into a plurality ofsections, each of which is controlled by the corresponding controlstation 14. Such a control configuration is called decentralized(distributed) control and the plant control monitoring system thatexecutes the decentralized control is generally called a distributedcontrol system (DCS). The distributed control system is widely used invarious traffic monitoring control systems or environment controlsystems, in addition to various manufacturing plants or power plants.

The control station 14 receives the process state signal output from thesensor 11 or the like. Based on the signal, the control station 14performs prescribed operation, and outputs a control signal (operationsignal). In accordance with the control signal, the actuator of thevalve 12 or the like, the device or equipment or the like is controlled.

The control station 14 contains a reference value (reference signal)corresponding to each device or equipment. The reference value isreferenced for normal operation of the device or equipment. The controlstation 14 compares the process state signal to the reference signal. Insome cases, the control station 14 performs a required operation using aplurality of process state signals and compares the resulting processsignal to the reference signal. When judging that the operation of adevice or equipment is in a deviation state, the control station 14outputs an alarm signal and causes the display device 15 to display analarm.

The devices or equipment are individually given tag numbers(identification numbers) to identify themselves. These tag numbers areset and stored by the control station 14. Input/output signalsassociated with the devices or equipment are managed by the controlstation 14 based on the tag numbers.

The display device 15 comprises a display 16 and a picture controller 17(picture switching means 17). The display 16 displays a picturerepresenting a process state of the plant 10. The picture controller 17causes the display 16 to display the picture representing the processstate, and performs switching of a picture displayed on the display 16as desired. The display device 15 is configured to represent the processstate signal by means of symbols as shown in the Figures.

The control system of the plant 10 is divided into the plurality ofcontrol sections (decentralized control), and each of the controlsections is controlled by the corresponding control station 14. Thecontrol station 14 hierarchically divides the devices or equipmentincluded in the plant 10 into predetermined groups. The predeterminedgroups refer to groups each including devices or equipment so as to beassociated with one another within the plant 10. The display device 15is capable of displaying a lowermost first layer picture and an upperlayer picture in the hierarchically divided groups. This display device15 has a picture structure capable of displaying a plurality of layerpictures. The first layer picture is a picture representing theoperating state for each device or equipment. The upper layer picturerefers to a picture representing the operating state of the group ofdevices or equipment associated with one another within the plant 10.

FIG. 2 shows a picture (graphic picture) 18 displayed by the displaydevice 15. In FIG. 2, the above-identified first layer picture isdisplayed.

The graphic picture (first layer picture) 18 represents one of stepsinto which the plant 10 is divided in a process flow diagram (PFD) form(or P & ID form: piping & instrument diagram form). That is, the firstlayer picture 18 displays one step of the plant 10. The picture 18 is adetailed representation of the devices or equipment, sensors, andinput/output signals associated with the devices or equipment by meansof diagrams, texts, etc.

The display device 15 is capable of displaying the upper layer pictureas described above. That is, the display device 15 has picturesrepresenting the steps in the block form so that relation among thesteps or flow of the steps within the plant 10 is known. These picturesare selected and displayed on the display 16 as desired. This pictureswitching is performed by the picture controller 17.

FIG. 3 is a view showing a list of pictures capable of being displayedby the display device 15. That is, a picture structure of the displaydevice 15 is switched and displayed.

In FIG. 3, reference numerals 19 to 23 denote first layer pictures. Inthese pictures, the devices or equipment are grouped for each step so asto be associated with one another. By selecting one of the first layerpictures 19 to 23, the operation in the step corresponding to thepicture is monitored. It should be appreciated that one step is notnecessarily represented by one picture, but, for example, when one stepincludes a number of devices or equipment, the first layer picture maybe divided into a plurality of pictures, or conversely, a plurality ofsteps may be represented by one picture.

Reference numerals 24 to 26 represent process-base layer pictures. Inthese pictures, the steps within the plant 10 are grouped for eachprocess so as to be associated with one another. By selecting one of theprocess-base layer pictures 24 to 26, the operation of the processcorresponding to the picture can be monitored. Reference numeral 27denotes a plant layer picture. The picture represents a list ofprocesses within the plant 10, and hence the entire plant 10.

In this embodiment, the entire plant 10 to be monitored by the operatoris hierarchically divided and displayed according to a purpose ofmonitoring, an operator's role, or the like. The entire plant 10 isdisplayed by the plant-base layer picture 27 (upper layer picture), theprocess-base layer pictures 24 to 26 (upper layer pictures) and thefirst layer pictures 19 to 23.

Herein, the “plant” is comprised of the plurality of processes and isdefined as a unit for manufacturing products. The “process” is comprisedof the plurality of “steps” and is defined as a unit for controllingkinds or quantity of the products independently within the plant. Withregard to plant related installation, such as auxiliary material orutility facility, the process may be defined for each function based onauxiliary material, utility, recovery, or the like. The “step” iscomprised of a set of “a plurality of equipment” and is defined ashaving a chemical engineering unit function (e.g., unit operationfunction such as reaction, distillation, extraction, absorption, ordrying). Minimum units of installation included in the plant is definedas the “equipment.” The equipment include pumps, tanks, distillationtowers, heat exchangers, compressors, refrigerators, reactors, driers,transports, valves (control valves, remote valves, or the like), etc.Piping or instruments include a temperature indicator, a flow rateindicator, a pressure indicator, a liquid level indicator, adensitometer, hygrometer, etc.

The picture structure of the display device 15 is not intended to belimited to the above. For example, a set of plural related plants may bedefined as an “area” and an operating state of the “area” may bedisplayed as the “plant-base layer picture” as the upper layer pictureof the process-base layer picture. In the same manner, it is possible toprovide upper layer pictures of groups, representing a “factory” as theentire factory such as a set of plural plants or areas, a “manufactory”or a “factory group” as a set of several factories, etc. Such groupingmay be suitably determined according to a purpose of monitoring theentire operation by the plant control monitoring system 13.

FIG. 4 schematically shows an example of picture switching by thedisplay device 15. In FIG. 4, the plant-base layer picture 27, theprocess-base layer picture 24 as a lower layer picture of the plant-baselayer picture 27, and the first layer picture 20 as a lower layerpicture of the process-base layer picture 24 are sequentially displayed.

FIG. 4 shows that control of two plants, i.e., a X plant and a Y plantare being monitored on the plant-base layer picture 27. The X plant andthe Y plant are each divided into three sections on the picture. Each ofthe plants includes a plurality of processes. For example, in the Yplant, the section displayed in the uppermost stage includes Y-1 to Y-4processes. Each of the processes is comprised of a plurality of steps Ato E. In this case, the picture controller 17 switches the plant-baselayer picture 27 to the process-base layer picture 24, or the like, andfrom the process-base layer picture 24 or the like, to the first layerpicture 20, or the like.

Next, the pictures displayed by the display device 15 will be describedin conjunction with their respective functions.

(1) Plant-Base Layer Picture

FIG. 5 shows an example of the plant-base layer picture. The plant-baselayer picture 31 represents that the operation is monitored for eachplant. FIG. 5 shows that plants A to C are being monitored. Also, FIG. 5represents each of the plants in a graphic form and processes or stepsassociated with one another within the plants in a block form. With thisconfiguration, the flow of the processes within the plants can bemonitored.

In the manner shown in FIG. 4, switching from the plant-base layerpicture 31 to the process-base layer picture or the first layer pictureis performed by touching or clicking a mouse on the process or steprepresented in the block form. The picture controller 17 allows pictureswitching by such one touch operation. By clicking the processrepresented in the block form, the process-base layer picture (see FIG.6) representing the process is displayed.

When disorder or abnormality (deviation state) occurs in any one of theprocesses or steps within the plants, the control station 14 raises analarm as described above. Simultaneously, the control station 14 changescolor of the process or step which is represented in the block form orcause the same to blink. That is, the control station 14 changes adisplay configuration of the picture. The change in the displayconfiguration might include only color change, color change andblinking, or only blinking. Hereinafter, the change in the displayconfiguration is called “color change or the like.”

In this embodiment, when the deviation state occurs, the alarms raisedin an arbitrary process or step within the plant are grouped. When thealarm is raised in a step (e.g., alarm appears in the first layerpicture 20 displayed in FIG. 4), color change or the like occurs in theprocess-base layer picture 24 (Y-4 process B in FIG. 4) and theplant-base layer picture 27 (uppermost stage of the Y plant in FIG. 4)which are associated with this step.

A condition for such grouping may be set. One condition is that alarmsare grouped regardless of their kinds when they are raised. Anothercondition is that, when several predetermined deviation states occur(alarm is raised when the several deviation states simultaneously occur,instead of being raised independently for each deviation state), thealarms are grouped. It is judged that the alarm is raised based on oneof these conditions, from the color change or the like, or change ofblinking position. These conditions are easily set by system programmingin the control station 14.

When the alarm is raised, blinking is displayed, and at the time when anoperator has checked the alarm, the blinking may stop and display maycontinue.

Further, in this embodiment, alarms are rated in the order of importanceaccording to the kind of the alarms. This rating is easily set by systemprogramming in the control station 14. The rating of alarms isdetermined depending on effects of these alarms on safety, productivity,product quality, and the like of the plant. For example, the alarms maybe displayed as red, orange, and yellow in the order of importance.

When a plurality of alarms are raised simultaneously within the sameblock, the alarm with higher importance is prioritized and displayed.Thereby, while the operation of the plant 10 is monitored, the alarmwith higher importance is dealt with, with priority. Further,advantageously, in the case where an alarm with lower importance israised and an alarm with higher importance is raised later, the operatordoes not miss the alarm with higher importance raised later.

Moreover, process data which is an important factor in operationmanagement can be displayed on the plant-base layer picture 31. Thisallows the operation of the plant to be well monitored.

(2) Process-base Layer Picture

FIG. 6 shows an example of a process-base layer picture. A process-baselayer picture 32 represents various processes included in the plant A inFIG. 5 in the graphic form and steps in the processes in the block form.This picture allows a flow of processes to be monitored.

By touching or clicking a mouse on the step represented in the blockform, i.e., by one touch, the process-base layer picture 32 is switchedto a first layer picture (see FIG. 7) representing the step. The firstlayer picture is also represented in the graphic form as mentionedlater.

When disorder or abnormality (deviation state) occurs in a step withineach process, the control station 14 raises an alarm, and performs colorchange or the like of the portion displayed in the block form, asdescribed above.

Also, when a deviation state occurs, the raised alarms are grouped, asdescribed above. The condition for such grouping of the alarms can beset in the same manner as described above. One condition is that alarmsare grouped regardless of their kinds when they are raised. Anothercondition is that, when several predetermined deviation states occur,(alarm is raised when the several deviation states simultaneously occur,instead of being raised independently for each deviation state), thealarms are grouped. It is judged that the alarm is raised based on oneof the conditions, from the color change or the like, or change ofblinking position. These conditions are easily set by system programmingin the control station 14.

When the alarm is raised, blinking is displayed, and at the time whenthe operator has checked the alarm, the blinking may stop and displaymay continue.

Further, in this embodiment, the alarms are rated in the order ofimportance. This rating is easily set by system programming in thecontrol station 14. The rating of alarms is determined depending oneffects of these alarms on safety, productivity, product quality, andthe like of the plant. For example, the alarms may be displayed as red,orange, and yellow in the order of importance.

When a plurality of alarms are raised simultaneously within the sameblock, the alarm with higher importance is prioritized and displayed.Further, as shown in FIG. 6, process data which is an important factorin operation management can be displayed on the process-base layerpicture 32. This allows the operation of the plant to be well monitored.

(3) First Layer Picture

FIG. 7 shows an example of a first layer picture. The first layerpicture 33 is a graphic picture of a process flow diagram (PFD) in whicha process flow of steps included in the plant A is described in a P& ID(piping & instrument diagram) form. This picture represents in detaildevices or equipment and sensors for controlling these device orequipment and input/output signals of these devices or equipment bymeans of diagrams, symbols, texts, and so forth. The picture representsassociation among the devices or equipment and piping within each step,or flow of them.

It should be appreciated that one entire step is represented by thefirst layer picture 33, but one step may be divided into a plurality offirst layer pictures, for example, when one step includes numerousdevices or equipment.

In this embodiment, the process state of the device or equipment isrepresented based on signals output from the devices or equipment(process state signals). Thereby, in addition to monitoring an operationstate of each step, control and producing states are managed. Also,means for automatically or manually operating an actuator of a valve orthe like, the device or equipment, or the like, in accordance with acontrol output (operation signal) (i.e., operation or the like fordealing with the alarm) can be displayed on the picture. This allows theoperation of the process to be monitored, or required judgment andoperation to be carried out. Therefore, when an alarm is raised in thedisplayed step, the state of alarm is displayed by color change or thelike of the diagram, symbol, text, and the like. In addition,information for dealing with the alarm is displayed.

The first layer picture 33 in FIG. 7 is provided with a means forperforming switching to a picture necessary for monitoring the operationof the plant (another picture relating to the picture in FIG. 7). Inother words, the first layer picture 33 is provided with a means forperforming switching to a picture representing a subsequent or previousstep of the step in this process, an operation picture for carrying outoperation of the device or equipment belonging to the step, or picturesof the other associated steps. Besides, the picture 33 is provided witha means for performing switching to pictures in upper layers, such as aprocess or a plant to which the step belongs, which will be described inlater.

The above-mentioned picture structure may be changed as follows. Whenthe plant does not have a plurality of processes, or when the plant hasthe plurality of processes, but steps within the plant are few,depending on the scale or features of a target plant, a picture for eachprocess may be dispensed with. In that case, a two-layer structureincluding the plant-base layer picture and the first layer picture, or atwo-layer structure including a plurality of process-base layer picturesand the first layer picture may be set. In summary, depending on thescale of the plant, the picture structure for controlling and monitoringthe plant may be layered as desired.

(4) The Other Function

As shown in FIGS. 5 to 7, the plant-base layer picture, the process-baselayer picture, and the first layer picture have simple display portions35 for simply displaying other processes, plants, and the like.

The simple display portions 35 are displayed on the plant-base layerpicture and the like, by the display device 15. With regard to thesimple display portion 35, the alarms are grouped in the mannerdescribed above. Therefore, when an alarm appears in a layer picturedifferent from a layer picture being displayed, it is checked that thealarm has been raised, from color change or the like of thecorresponding portion of the simple display portion 35. Thereby, theoperator can immediately know which of layer pictures the alarm appearson. In addition, the operator can perform switching to that picture andperform a required operation.

An example of a display configuration of the simple display portion 35is that, on each first layer picture, a process-base layer picture or aplant-base layer picture on an upper layer is simply displayed. Anotherexample is that, on each process-base layer picture, a process-baselayer picture or a plant-base layer picture on the same or upper layeris simply displayed. A further example is that, on each plant-base layerpicture, a plant-base layer picture or a process-base layer picture onthe same or lower layer is simply displayed. By touching or clicking themouse on a layer group picture of the simple display portion 35,switching to this picture is achieved. This function is performed by theabove-mentioned picture controller 17.

FIG. 8 shows an example of the simple display portion 35. In FIG. 8, anevent that the an alarm has been raised in a B-1 process of the plant Bis represented by color change or the like of the simple display portion35. By touching or clicking the mouse on this portion of the picture,switching to a plant-base layer picture including the plant B or anprocess-base layer picture including B-1 process in a lower layer can beperformed.

The above-mentioned function dramatically extends the range of the plant10 which can be monitored by one operator. In other words, a wider rangeof operation of the plant can be monitored with fewer pictures. Inaddition, a monitoring level can be standardized. Further, the operatorwould not miss a deviation state, and would find out disorder orabnormality of the plant 10 or a sign of it in an earlier stage.Moreover, the number of loops which may be monitored by one operator isincreased.

Then, in this embodiment, a guidance picture 36 mentioned later isdisplayed. The guidance picture serves to offer support informationrequired for the operation of the plant 10 when the alarm is raised. Asshown in FIG. 9, the guidance picture 36 displays information relatingto specification of a cause of the alarm, detailed information relatingto a content of the alarm, information relating to how to deal with thealarm or an operation required for dealing with the alarm, and the like.

When the alarm is raised, a fact that the guidance picture is present oneach picture such as the plant-base layer picture, the process-baselayer picture or the like is represented by means of a symbol ordiagram. When the alarm is raised, the presence of a guidance picturecorresponding to the alarm is known by color change or the like of thesymbol or the diagram.

The color change or the like is performed such that the alarm isdisplayed as red, orange, and yellow in the order of importance of thealarm. When two or more alarms are raised simultaneously on a picture, apriority for dealing with the alarms is established.

Further, in this embodiment, by clicking the mouse on or touching thesymbol or the diagram on the picture, the guidance picture appears. Theabove-identified picture controller 17 makes it possible to performswitching to the guidance picture by one touch. Since the guidancepicture is displayed and the operator performs operation according tothe guidance, the alarm can be easily dealt with regardless of anexperience or skill of the operator.

The guidance picture is equipped with functions as described below.

The functions are to display detailed information by the guidancepicture.

This will be described with reference to the guidance picture 36 in FIG.9. The detailed information can be displayed on the guidance picture 36.

(a) Check of Content of Alarm

This function is to describe in detail the state of disorder orabnormality corresponding to the alarm. Also, the function has a meansfor switching to pictures required for displaying process data and thelike associated with the alarm, and checking and judging a state of thealarm. That is, other pictures required for judgment is switched fromthis picture.

(b) Operation for Dealing with Alarm

This function is to display a content of an action required for dealingwith the alarm. Also, the function is to display a picture representingan operation required for the action or a picture required for theoperation. As in (a), the function is to display an operation methodrequired for dealing with the alarm, a picture required for carrying outthe method, or the like.

(c) Specification of Cause of Alarm

This function is to display data or the like relating to an alarm toallow a cause of the alarm to be checked. The function is to alsodisplay other pictures required for checking. Further, the function isto make setting so that the cause of the alarm is automaticallyspecified. In this case, a program for automatically specifying thecause of the alarm is incorporated into a control station, a workstation, or the like connected to the plant control monitoring system13, and the result of the specified cause is displayed on the guidancepicture.

(d) Display of Other Operating States

For example, a setting may be made so that a tray performance of adistillation tower in operation, a surging area of a compressor, or thelike can be displayed. These information are difficult to represent onlyby means of numeric values or texts, and therefore, representation usinga graph, a diagram, and so forth facilitates checking of them in realtime. Thereby, all support information relating to operation andmanagement of the plant 10 can be displayed as well as the informationfor dealing with disorder or abnormality of the plant 10 and theoperation method, thus supporting the operation by the operator.

In the case where alarms requiring guidances are few, as soon as thealarm is raised, the corresponding guidance picture can be immediatelydisplayed.

As shown in FIG. 10, a list picture 37 of guidance may be provided. Thelist picture 37 is effective for the case where there are many alarmsrequiring guidances, and symbols or diagrams indicative of the presenceof the guidance pictures 36, corresponding to the alarms, cannot bedisplayed in a one to one correspondence on a picture.

The list picture 37 provides an index of guidance corresponding to eachalarm. The list picture 37 may be first displayed and then switched to arequired guidance picture 36.

This method is more effective where the picture in the upper layer suchas the plant-base layer picture or the process-base layer picture isdisplayed, that is, where a picture displays a great many alarms byincluding a plurality of devices or equipment, or a number of processesand steps.

When the list picture 37 of guidance is switched to the guidance picture36, the above mentioned picture controller 17 may be used. The outlineis shown in FIG. 11.

This operation may be performed by one touch operation, such as touching(pointing to) or clicking a mouse on the picture. Further, the operatorcan know the presence of guidance by color change or the like of theportion to be displayed in the list picture 37. The use of the listpicture 37 of such guidance allows the guidance pictures 36corresponding to a number of alarms to be displayed on each layerpicture.

The guidance picture 36 or the list picture 37 of guidance may bedisplayed, for example, on the display 16 on which the plant-base layerpicture, the process-base layer picture, the first layer picture, or thelike is displayed, for example, in an overlapped state in a windowformat. This is achieved by using a general window format in a computersystem.

In addition, the picture switching is freely performed. This functionallows the operator to operate the plant 10 or perform an operation fordealing with the alarm on a picture other than the guidance picture,while checking the content of the guidance.

As should be appreciated from the foregoing, the alarm can be dealt withquickly and appropriately using the guidance picture 36 without skillsof the operator. This is because the guidance picture 36 eliminates aneed for the operator to learn causes of the alarms, operations forchecking the alarms, etc.

Besides, since the alarms are grouped and the picture is quicklyswitched, the operator need not predict or remember the picture on whichthe alarm appears. This eliminates difference in the operations due tovariation in skills of operators, and hence standardizes operation,judgment, and handling. Further, a monitor range per operator can beextended and control of the plant 10 is monitored with high precision.

INDUSTRIAL APPLICABILITY

As should be appreciated from the foregoing, in accordance with thepresent invention, the following effects are provided.

(1) Since the display device has a picture structure of a plurality oflayers and picture switching is performed as desired, the operator neednot remember the pictures, unlike the prior arts. When the alarm israised, the picture including the device or equipment in a deviationstate can be simply displayed regardless of experience or skill of theoperator. Consequently, the operator can quickly and accurately detectdisorder or abnormality in the process state which has occurred in theplant.

(2) In particular, the guidance picture configured to represent thealarm state and support information for dealing with the alarm, allowsthe operator to know what deviation state has occurred, and appropriatemeans for dealing with the alarm can be carried out irrespective of theexperience or skill of the operator. This standardizes the operation fordealing with the alarm and hence operation and management of the plant.

(3) In addition, since picture switching is performed by one touchoperation, and the picture including the device or equipment in thedeviation state can be quickly displayed irrespective of the experienceor skill of the operator, the means for dealing with the alarm can becarried out quickly and appropriately irrespective of experience orskill of the operator.

1. A plant control monitoring system comprising: a display deviceconfigured to display operating states of a plurality of devices orequipment included in each process of a plant by using predeterminedsymbols; and a processing unit having an alarm output portion foroutputting an alarm signal and causing the display device to display analarm, when judging that an operation of a device or equipment is in adeviation state; the display device including: a first layer pictureconfigured to represent an operating state for each device or equipment,and an upper layer picture configured to represent an operating statefor each of groups into which devices or equipment are hierarchicallydivided so as to be associated with one another; a simple display meansfor simply displaying a simple display portion configured to simplydisplay an operating state of a lower layer group, the same layer group,or an upper layer group, on the first layer picture or the upper layerpicture; and a picture switching means for switching picture display asdesired.
 2. The plant control monitoring system according to claim 1,wherein the upper layer picture includes at least: a plant-base layerpicture configured to represent the entire plant as having groups intowhich steps represented by the first layer pictures are divided so as tobe associated with one another.
 3. The plant control monitoring systemaccording to claim 1, wherein the upper layer picture includes at least:a process-base layer picture configured to represent groups into whichsteps represented by the first layer pictures are divided for eachprocess; and a plant-base layer picture configured to representprocesses represented by the process-base layer pictures as beingintegrated for each plant.
 4. The plant control monitoring systemaccording to claim 1, wherein the alarm output portion includes: analarm grouping means configured to display the alarm in a first layerpicture associated with the alarm and an upper layer picture associatedwith the first layer picture, when outputting the alarm signal.
 5. Theplant control monitoring system according to claim 4, wherein the alarmgrouping means includes: a display configuration changing means forchanging a display configuration according to importance of the alarm.6. The plant control monitoring system according to claim 1, wherein thedisplay device includes: a guidance picture configured to represent adeviation state and support information for dealing with the deviationstate, when the alarm is raised.
 7. The plant control monitoring systemaccording to claim 5, wherein the display device includes: a guidancepicture configured to represent a deviation state and supportinformation for dealing with the deviation state, when the alarm israised.
 8. The plant control monitoring system according to claim 6,wherein the display device includes: a means configured to display apicture indicating that the guidance picture is prepared, when the alarmis raised.
 9. The plant control monitoring system according to claim 7,wherein the display device includes: a means configured to display apicture indicating that the guidance picture is prepared, when the alarmis raised.
 10. The plant control monitoring system according to claim 6,wherein the picture switching means includes: a means configured todisplay the guidance picture, when the alarm is raised.
 11. The plantcontrol monitoring system according to claim 7, wherein the pictureswitching means includes: a means configured to display the guidancepicture, when the alarm is raised.
 12. The plant control monitoringsystem according to claim 8, wherein the picture switching meansincludes: a means configured to display the guidance picture, when thealarm is raised.
 13. The plant control monitoring system according toclaim 9, wherein the picture switching means includes: a meansconfigured to display the guidance picture when the alarm is raised. 14.The plant control monitoring system according to claim 10, wherein thepicture switching means includes: a means configured to display theguidance picture or a picture indicating that the guidance picture isprepared, when an alarm having a predetermined rating is raised.
 15. Theplant control monitoring system according to claim 11, wherein thepicture switching means includes: a means configured to display theguidance picture or a picture indicating that the guidance picture isprepared, when an alarm having a predetermined rating is raised.
 16. Theplant control monitoring system according to claim 12, wherein thepicture switching means includes: a means configured to display theguidance picture or a picture indicating that the guidance picture isprepared, when an alarm having a predetermined rating is raised.
 17. Theplant control monitoring system according to claim 13, wherein thepicture switching means includes: a means configured to display theguidance picture or a picture indicating that the guidance picture isprepared, when an alarm having a predetermined rating is raised.
 18. Theplant control monitoring system according to claim 6, wherein theguidance picture is configured to represent a plurality of supportinformation for dealing with the alarm.
 19. The plant control monitoringsystem according to claim 7, wherein the guidance picture is configuredto represent a plurality of support information for dealing with thealarm.
 20. The plant control monitoring system according to claim 8,wherein the guidance picture is configured to represent a plurality ofsupport information for dealing with the alarm.
 21. The plant controlmonitoring system according to claim 9, wherein the guidance picture isconfigured to represent a plurality of support information for dealingwith the alarm.
 22. The plant control monitoring system according toclaim 10, wherein the guidance picture is configured to represent aplurality of support information for dealing with the alarm.
 23. Theplant control monitoring system according to claim 11, wherein theguidance picture is configured to represent a plurality of supportinformation for dealing with the alarm.
 24. The plant control monitoringsystem according to claim 12, wherein the guidance picture is configuredto represent a plurality of support information for dealing with thealarm.
 25. The plant control monitoring system according to claim 13,wherein the guidance picture is configured to represent a plurality ofsupport information for dealing with the alarm.
 26. The plant controlmonitoring system according to claim 14, wherein the guidance picture isconfigured to represent a plurality of support information for dealingwith the alarm.
 27. The plant control monitoring system according toclaim 15, wherein the guidance picture is configured to represent aplurality of support information for dealing with the alarm.
 28. Theplant control monitoring system according to claim 16, wherein theguidance picture is configured to represent a plurality of supportinformation for dealing with the alarm.
 29. The plant control monitoringsystem according to claim 17, wherein the guidance picture is configuredto represent a plurality of support information for dealing with thealarm.
 30. The plant control monitoring system according to claim 6,wherein the guidance picture has a list picture configured to representa list of a plurality of guidances.
 31. The plant control monitoringsystem according to claim 7, wherein the guidance picture has a listpicture configured to represent a list of a plurality of guidances. 32.The plant control monitoring system according to claim 8, wherein theguidance picture has a list picture configured to represent a list of aplurality of guidances.
 33. The plant control monitoring systemaccording to claim 9, wherein the guidance picture has a list pictureconfigured to represent a list of a plurality of guidances.
 34. Theplant control monitoring system according to claim 10, wherein theguidance picture has a list picture configured to represent a list of aplurality of guidances.
 35. The plant control monitoring systemaccording to claim 11, wherein the guidance picture has a list pictureconfigured to represent a list of a plurality of guidances.
 36. Theplant control monitoring system according to claim 12, wherein theguidance picture has a list picture configured to represent a list of aplurality of guidances.
 37. The plant control monitoring systemaccording to claim 13, wherein the guidance picture has a list pictureconfigured to represent a list of a plurality of guidances.
 38. Theplant control monitoring system according to claim 14, wherein theguidance picture has a list picture configured to represent a list of aplurality of guidances.
 39. The plant control monitoring systemaccording to claim 15, wherein the guidance picture has a list pictureconfigured to display a list of a plurality of guidances.
 40. The plantcontrol monitoring system according to claim 16, wherein the guidancepicture has a list picture configured to represent a list of a pluralityof guidances.
 41. The plant control monitoring system according to claim17, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 42. The plant controlmonitoring system according to claim 18, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 43. The plant control monitoring system according to claim19, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 44. The plant controlmonitoring system according to claim 20, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 45. The plant control monitoring system according to claim21, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 46. The plant controlmonitoring system according to claim 22, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 47. The plant control monitoring system according to claim23, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 48. The plant controlmonitoring system according to claim 24, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 49. The plant control monitoring system according to claim25, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 50. The plant controlmonitoring system according to claim 26, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 51. The plant control monitoring system according to claim27, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 52. The plant controlmonitoring system according to claim 28, wherein the guidance picturehas a list picture configured to represent a list of a plurality ofguidances.
 53. The plant control monitoring system according to claim29, wherein the guidance picture has a list picture configured torepresent a list of a plurality of guidances.
 54. The plant controlmonitoring system according to claim 1, wherein the picture switchingmeans includes: a means configured to perform switching to a layerpicture different from a layer picture being displayed, or the guidancepicture, by one touch operation on the layer picture being displayed.